Reinforced foam building components and structures made therefrom

ABSTRACT

The instant invention features reinforced foam building components, and methods to form affordable, energy efficient structures assembled from a plurality of panel assemblies with common features. The structures are anchored to the foundation by straps passing through the panel assemblies and attached to the foundation. The structure, the panel assemblies, the anchoring system and the assembly methods, comprise a building system for dwellings and other structures.

BACKGROUND OF THE INVENTION:

[0001] 1. Field of Invention

[0002] This invention relates to static structures, specifically toimproved components and methods to build advantageous dwellings or otherenclosures.

[0003] 2. Discussion of Prior Art

[0004] Building structures with foam panels have been developed byothers as an alternative to wood methods to reduce costs and improveenergy efficiency. For example, the wall panels in patents 5,279,089 toGulur, 1994 Jan. 18, in 5,787,665 to Carlin et al., 1998 Aug. 4, and in4,641,468 to Slater, 1987 Feb. 10, use metal framing elements tostrengthen and for assembly into structures. The metal framing addscomplexity to the design and creates thermal paths that circumvent thebenefits of the insulating foam. Other panels in 4,628,650 to Parker,1986 Dec. 16, introduce wood framing elements to the foam. These wallsare complex, heavy and expensive to construct. The thermal performance,while better than metal framing, is degraded.

[0005] Other wall panel joints in 6,065,259 to Clear, 2000 May 23, andin 2,056,290 to Alexander et al., 1991 Oct. 15, provide means tofabricate structures from a plurality of panels. These joints requirecomplex means to fabricate the unique shapes and increase costs. Thesemetal joints create thermal shunt paths that deteriorate the energyefficiency of the structure. The panel joints in 6,035,584 to Barreto,2000 Mar. 14, include sealing components, improving the thermalproperties but add further to the complexity and costs of the structure.

[0006] Wall panel passageways in 4,628,650 to Parker, 1986 Dec. 16, areprovided for easy wire routing. The passageways are interior to thepanels which requires time consuming cutting to create. The applicationis limited to wall panels.

[0007] In summary, the prior art demonstrates numerous attempts to usefoam to build energy efficient structures that are inherently complex indesign, complex in assembly methods and costly.

[0008] Objects and Advantages

[0009] The present invention provides an inexpensive, easilyconstructed, energy efficient dwelling unit. Accordingly, severalobjects and advantages of my invention are:

[0010] (a) to provide a reinforced foam panel as a fundamentalconstruction unit that is simple to fabricate, contains a strengtheningelement and a multipurpose passageway for advantageous purposes;

[0011] (b) to provide low cost by using common materials, features andmethods for floor, wall and roof panels;

[0012] (b) to provide methods of assembly and joining that avoidscomplex joints, sealing strips and fasteners but is, nevertheless,strong, thermally advantageous and easy to do at the construction site;

[0013] (c) to provide doors and windows in a manner consistent withother wall panels;

[0014] (d) to provide an anchoring system that resists high winds, lowpressures, and earthquake forces;

[0015] (e) to provide methods to rapidly and easily assemble a pluralityof construction components into affordable and energy efficientstructures;

[0016] (f) to provide the structure with the benefits of strength,energy efficiency, fire-resistance and water resistance of the foammaterial;

[0017] (g) to limit the skilled labor, especially carpenters, requiredbuilding the structure.

[0018] The present disclosure will, for convenience and clarity, relateto and disclose a preferred form of dwelling structure. It will beappreciated that the structure, with modifications, can be used andadapted as a commercial structure or as a structure of some unspecifieduse. Consequently, the present invention should not be limited.

[0019] The above summary and further objects, features, variations andadvantages of the present invention will become apparent from theaccompanying drawings and the following detailed description of theinvention.

SUMMARY

[0020] A building construction component, structured in accordance withone aspect of the invention, includes an elongated slab of rigid foaminsulating material, such as expanded polystyrene, with density andthickness appropriate for the intended use, exhibiting a recess disposedalong one of the longitudinal sides of the slab, wherein a reinforcingmember is fixed, a portion of the recess remaining open as a passagewayfor wiring or other elements. In one form of the invention, theelongated slab has recesses disposed along both of the longitudinalsides with reinforcing members and passageways provided therefore onboth sides. The overall dimensions of the slabs are selected, inaccordance with the density and thickness of the foam, to construct adwelling with a plurality of the building construction units used in thefloor, walls and roof. Variations on the size and shape of the recesswould accommodate a variety of reinforcing members and create a varietyof passageways. In the preferred embodiment the recess is off-center toprovide advantages in bending strength, ease of electrical connectionsand a large contiguous area for bonding. The reinforcing member is fixedinto the recess by interference fit, adhesive bonding or other suitablemeans.

[0021] The reinforced foam slabs of the building construction units,with windows and doors fixed to the interior thereof, are interspersedas required by the design of the structure. Reinforcing members andpassageways, on one or both longitudinal sides, provide strength andspace for wiring or other elements. In one form of the invention, aprocess is described that includes (1) cutting an appropriate opening inthe foam slab, (2) bonding the window in the resulting opening, and (3)bonding a portion of the removed foam to create a flat surface. Doorpanels are completed in a similar manner. A structure in one of theembodiments, comprising a plurality of the building constructioncomponents of the floor, roof, and wall panels interspersed with doorpanels and window panels, is fabricated by applying a polyurethane orsimilar adhesive to the mounting area of the foundation for the firstfloor panel. The first floor panel is placed on the adhesive and allowedto bond. Next, adhesive is applied to the foundation area for the secondpanel and the surface that will abut the first panel. The second panelis placed and allowed to bond. The process is repeated for eachadditional panel that makes up the floor. Note that the adhesive on theside surfaces is applied in a manner to create a continuous joint thatis sealed against ingress of air and moisture. Wall panels are added toedge of the floor by adhesive bonding to the floor and adjacent panelsin a manner similar to the floor panels. Window and door panels areinterspersed, each panel bonded as the foregoing panels, to meet thedesign requirements of the structure. The foam is of sufficientthickness that the wall sections are free standing and can be easilypositioned into a planar surface. In one embodiment of the invention,the walls are supported by an aligning means during the bonding processto improve the flatness of the resulting wall. Roof panels are bonded inplace in a like manner. Long roof spans use interior walls to providesupport. Joints on the interior of the structure are bonded to controlnoise and air passage between spaces. The bonding material fills andseals the joint area; thereby creating a building envelope that issealed for moisture and air leakage. The foregoing process produces acomplete structure meeting the objects of the invention.

[0022] One use of the passageways is to accommodate a storm strapsystem. This is accomplished by sizing and deploying the roof and wallpanels in such a manner that the passageway of the wall and roof panelsare in close proximity. A strap, such as a metal band of sufficientstrength, traverses the passageway of the one wall panel, one or moreroof panels, and the opposite wall panel. The strap has terminatingmeans to attach to the foundation anchoring means. A plurality of stormstraps is deployed to provide sufficient strength for the anticipatedwind, pressure and earthquake loads. The straps can be inserted duringor after the envelope construction since the passageways are accessibleuntil cap pieces are added to complete the structure.

[0023] The building systems of the present invention, with minorvariations, can be used with a variety of foundation systems; forexample, pier supports, below grade foundations, or concreteslab-on-grade.

DRAWINGS

[0024] Typical embodiments of the invention will now be described, byway of example, with reference to the accompanying drawings. In thedrawings, closely related figures and items have the same number withalphabetic suffixes.

[0025]FIG. 1 is an elevation view of a typical structure;

[0026]FIG. 2 is a section view along line 2-2 in FIG. 1;

[0027]FIGS. 3A to 3E are top views of various foam slabs;

[0028]FIGS. 4A to 4D are enlarged top views of portions of the foamslabs exhibiting various recess areas, reinforcing elements and fixingmeans;

[0029]FIG. 5 is the front portion of the section view along line 5-5 inFIG. 1;

[0030]FIG. 6 is an exploded view of the window panel assembly

DETAILED DESCRIPTION

[0031] Preferred Embodiment

[0032] With reference now to the drawings, FIG.1 shows a simplifiedelevation view of a building structure 20 incorporating a plurality andcombination of wall panels 21, window panel assemblies 22, door panelassemblies 23, roof panels 24, and floor panels (Not Shown), allincorporating the elements of the present invention. Also shown areroof-to-wall caps 46, wall-to-wall caps 48 and floor-to-wall caps 50.

[0033] As shown in FIG. 1 and the section shown in FIG.2., the structure20 incorporates a plurality of wall panels 21 comprised of structuralfoam slabs 29A, molded or extruded from expanded polystyrene. In thepreferred embodiment, the foam slab 29A is strengthened by includingrecess area 26A (best seen in FIG. 3.), and reinforcing element 28Afixed into the recess area 26A with adhesive 27. The structure 20 mayinclude one or more window panel assemblies 22, comprised of structuralfoam units 33 and 34, and a window 36 fixed to the interior of the foamslab 33, which slab 33 has been shaped to provide a mounting surface 37.Foam slab 33 is strengthened by including recess area 26A, reinforcingelement 28A fixed into the recess area 26A with adhesive 27. These laterthree elements are off center to provide advantages in bending strength,ease of electrical connections and a large contiguous area for bonding.The structure 20 also includes one or more exterior door panelassemblies 23 comprised of structural foam slabs 32 shaped to provide amounting tang 35 sized appropriately for the door assembly 30. The foamslab 32 is strengthened by including recess area 26A, reinforcingelement 28A fixed into the recess area 26A with adhesive 27. Awall-to-wall cap 48 encloses the wall ends and adds passageway space inthe area of the junction whereby electrical wiring 52, telephone wire 54and video cable 56 are routed from floor to roof. The use of thepassageway shown in FIG. 2 is a typical one; other advantageous uses areanticipated.

[0034]FIGS. 3A to 3E show various foam slabs 29A to 29E. FIGS. 3B to 3Eshow variations in recess area 26A of foam slab 29A to new recess areas26B to 26D. The variations shown are representative of useful designsbut should not be viewed as a limitation of the invention. Additionalrecess area designs could arise from selections of reinforcing elementsor passageway requirements.

[0035]FIGS. 4A to 4D show portions of foam slab 29A and 29D, asrepresentative of foam slabs that are used for any of the constructionunits 21 through 24, exhibiting various means to fix the reinforcingelement to any of the foam slabs described herein. FIG. 4A shows a closefit of the interior wall of recess 26A (best seen in FIG. 3A) with steelstud 28A. The portion of recess area 26A not filled by the steel stud28A is passageway 31A. In FIG. 4B the steel stud 28A is placed in therecess 26D (best seen in FIG. 3C) which has a dovetail shape. Thedovetail shaped recess 26D design increases the ease of installation andincreases the retention force of the stud 28A. In FIG. 4C the stud 28Ais bonded with polyurethane or similar adhesive 27 into recess 26A (bestseen in FIG. 3A) In FIG. 4D the stud 28A is bonded with polyurethane orsimilar adhesive 27 into recess 26D (best seen in FIG. 3D).

[0036]FIG. 5 shows a vertical cross section of structure 20 along line5-5 of FIG.1. A floor panel assembly 25 is shown bonded with adhesive 27to foundation 40 containing anchor 42. Wall panel assembly 21 is bondedto floor panel assembly 25 and roof panel assembly 24 with adhesive 27.Each of the panel assemblies exhibits passageway 31B. As shown in FIG.5, the various panel assemblies, with recess areas located at thesurface of the joint are bonded in relative positions such that thepassageways are in close proximity thereby creating a continuous path.Anchoring strap 44 is shown attached to the anchor 42 and routed throughpassageway 31B of wall panel assembly 21 into passageway 31B of roofpanel assembly 24. The anchoring strap continues across the roof,through the opposite wall and connects to the anchor on the oppositeside of the foundation (not shown). A plurality of straps, placed inadditional passageways, of sufficient size and strength, anchors thestructure to the foundation to provide sufficient strength for theanticipated wind, pressure and earthquake loads. FIG. 5 also shows asection view of the adhesive joint 27 between abutting panel assemblies.The passageway may also used for various utility services; the figureshows, for example, electrical wiring 52, telephone wiring 54 and videocable 56 routing as shown in FIG. 2.

[0037]FIG. 6 is an exploded view of the window panel assembly 22. Thethree parts are: (1) Foam slab 33 with recess 26A disposed on both sidesand mounting area 37, (2) window assembly 36 and (3) foam window trimcomponent 34. The window assembly 36 is bonded with adhesive 27 (notshown) to mounting area 37. The foam window trim component 34 is thenbonded to window assembly 36 and foam slab 33 to complete the windowpanel assembly 22. A reinforcing stud 28A (best shown in FIG. 4) may befixed into recess 26A before or after the window is bonded in place.

[0038] The process of building a structure in accordance with thisinvention is described in the following. For example, consider thecomponents shown in FIGS. 1 and 5, a structure 20 of one of theembodiments of the present invention, comprising a plurality of thebuilding construction panel assemblies for the floor 25, roof 24, wall21, interspersed with window panels 22, and door panels 23, isfabricated by applying a layer of polyurethane or similar adhesive tothe area of the foundation 40 for the first floor panel. The first floorpanel assembly is placed on the adhesive and bonds to the foundation 40.Next, adhesive is applied to the foundation area for the second paneland the surface of the first panel that will abut the second. The secondpanel is placed and allowed to bond to the foundation 40 and the firstpanel. The process is repeated for each additional panel that makes upthe floor. Note that the adhesive on the side surfaces is applied in amanner to create a continuous joint that is sealed to air and moisturepassage. Wall panel assemblies are added to edge of the floor byadhesive bonding to the floor and adjacent panels in a manner similar tothe floor panels. Window and door panel assemblies are interspersed,each panel bonded as the foregoing panels, to meet the designrequirements of the structure. Roof panels are bonded in place in a likemanner. Long roof spans use interior walls to provide support the span.Bonding trim foam components 46, 50, and 48 between roof, floor and wallends respectively, completes the structure. The bonding provided by theinstant process produces a strong, energy efficient structure that issealed for moisture and air leakage. The process steps may be rearrangedin many ways to produce the structure; the specific sequence providedherein is not a limitation of the invention. For example, the first wallassemblies can be bonded to the floor as soon as sufficient floor panelassemblies are bonded to the foundation.

[0039] Building structures may also be fabricated from a combination ofthe components of the instant invention and other traditional materials.For example, the wall panel assemblies 21 may be used with a concretewall foundation and a conventional trussed roof finished with shingles.Details of the wall panel assemblies may vary from the preferredembodiment but remain within the scope of the invention.

[0040] Structure 20 has numerous advantages over buildings constructedusing conventional techniques, and in particular to typical wood framedconstruction. Structure 20 is energy efficient, easy to construct,incorporates common construction items, such as windows, avoidcomplexity in both prefabrication and on-site stages, and haspassageways throughout for anchoring, utility runs and other purposes.The net effect of these advantages is a structure that has lower costper square foot of usable space than conventional construction.

[0041] While the invention has been herein shown and described and whatis presently conceived to be the most practical and preferred embodimentthereof, it will be apparent that many modifications may be made withinthe scope of the invention, which scope is to be accorded the broadestinterpretation of the appended claims so as to encompass all equivalentmethods and devices.

I claim:
 1. A reinforced building component comprising: a foam slab,generally a rectangular parallelepiped with width and length greaterthan the thickness, a recess area disposed along the complete length ofa side that includes the shortest edge, a reinforcing member, a fixingmeans for securing said reinforcing member to said foam slab at thesurface defined by said recess area, and a passageway comprising thearea of said recess area not filled by said reinforcing member and saidfixing means.
 2. The reinforced building component of claim 1 whereinsaid foam slab is expanded polystyrene.
 3. The reinforced buildingcomponent of claim 1 wherein said recess area is a channel with uniformrectangular cross section.
 4. The reinforced building component of claim1 wherein said recess area is a channel with uniform dovetail crosssection.
 5. The reinforced building component of claim 1 wherein saidreinforcing member is a steel stud.
 6. The reinforced building componentof claim 1 wherein said fixing means is adhesive.
 7. The reinforcedbuilding component of claim 6 wherein said foam slab is polystyrene,said recess area is a dovetail, said recess area is offset from thecenterline of said side, said reinforcing member is a steel stud, andsaid adhesive is polyurethane.
 8. The reinforced building component ofclaim 1 wherein said fixing means is thermal welding.
 9. The reinforcedbuilding component of claim 1 wherein said recess area is offset fromthe centerline of the side.
 10. The reinforced building component ofclaim 1 further comprising a second recess disposed on the opposite sideof said foam slab.
 11. The reinforced building component of claim 10further comprising: a reinforcing member, and fixing means for securingsaid reinforcing member in said second recess area.
 12. A window panelassembly comprising said reinforced building component of claim Ifurther comprising: a window mounting surface area disposed in said foamslab, a window assembly, a fixing means to attach said window assemblyto said window mounting surface area, a window trim foam component, afixing means to attach said window trim foam component to said windowassembly and said foam slab.
 13. A door panel assembly comprising saidreinforced building component of claim 1 further comprising: a doormounting tang disposed in said foam slab a door and frame assembly afixing means to attach said door and frame assembly to said doormounting tang
 14. A method for constructing said window panel assemblyof claim 12 comprising (a) proving a reinforced building component ofclaim 1 (b) providing removal means for said foam slab (c) providing awindow assembly with a mounting flange (d) providing a window trim foamcomponent (e) use said removal means to provide a window mountingsurface in said reinforced foam building component sized for said windowassembly mounting flange (f) further use removal means to provide awindow opening perpendicular to said window mounting surface of saidreinforced building component (g) provide fixing means to secure saidwindow assembly to said mounting surface areas (h) providing fixingmeans to secure said window foam trim component to said window assembly(i) providing fixing means to secure said window foam trim component tosaid reinforced foam building component (j) fix said window assembly tosaid window mounting surface, (i) fix said window trim foam component tosaid window assembly and said foam slab
 15. A method for window panelassembly of claim 14 wherein said fixing means is adhesive. 16 A methodfor window panel assembly of claim 14 wherein said removal means is hotwire cutting.
 17. A method for constructing a door panel assemblycomprising (a) providing a reinforced building component of claim 1 (b)providing removal means for said foam slab (c) providing a door andframe assembly with mounting channel (d) providing fixing means tosecure said door frame assembly to said reinforced foam buildingcomponent (e) use said removal means to provide a door opening throughsaid reinforced building component (f) further use said removal means toprovide a door mounting tang in said reinforced building component (g)attach a door and frame assembly to said door mounting tang by applyfixing means to said door and frame assembly mounting channel to doormounting tang. 18 A static structure comprising at least one saidreinforced construction component of claim
 1. 19 A static structure ofclaim 16 further comprising said window panel assembly of claim
 7. 20 Astatic structure of claim 16 further comprising said door panel assemblyof claim
 8. 21. A method for an extended passageway in said staticstructure of claim 18 comprising: (a) providing a first reinforcedbuilding component of claim 1 (b) providing a second a second reinforcedbuilding component of claim 1 (c) locate said first reinforced buildingcomponent such that said passageway is in proximity to said passagewayof said second reinforced building component.
 22. A method forconstructing static structures from a plurality of said reinforcedbuilding components of claim 1 comprising: (a) providing a firstreinforced building component of claim 1 (b) providing a foundation forthe structure (c) apply fixing means to attach said first buildingcomponent on said foundation (d) providing a second reinforced buildingcomponent of claim 1 (e) apply fixing means to attach said secondreinforcing building component to said foundation and said first secondreinforced building component, (f) repeat steps (d) and (e) withadditional reinforced building components until the floor is complete(g) providing a third reinforced building component of claim 1 (h)applying fixing means to attach said third reinforced building componentvertically perpendicular to the edge of said floor, orientated with saidside of said foam slab containing said recess horizontally perpendicularto said edge of said floor. (i) repeat steps (g) and (h) with additionalreinforced building components until the walls are complete (j)providing a forth reinforced building component of claim 1 (k) applyingfixing means to attach said forth reinforced building componenthorizontally perpendicular to said walls, orientated with said side ofsaid foam slab containing said recess horizontally perpendicular to saidwall. (l) repeat steps (g) and (h) with additional reinforced buildingcomponents until the roof is complete
 23. A method for structureanchoring for static structures of claim 18 comprising (a) providing afoundation with structure anchoring means disposed in pairs on oppositeareas of said foundation (b) providing a static structure of claim 18with said extended passageways of claim 19 on said foundation (c)providing an anchoring strapping means (e) providing fixing means toattach said anchoring strapping means to said foundation anchoring means(f) routing said anchoring strapping means through said extendedpassageway in walls and roof panels to opposite said anchoring means (g)attach said anchoring strapping means to said anchoring means with saidfixing means (h) repeat steps (c) through (g) if more than one saidanchor strap is disposed
 24. An edge passageway comprising: a firstreinforced building components of claim 1, a second reinforced buildingcomponent of claim 1 orientated perpendicular and fixed to said firstreinforced building component, a trim foam component generallyrectangular in cross section with a portion of one corner removed, andfixing means to simultaneously attach said trim component to said firstreinforced building component and to said second reinforced buildingcomponent orientated to form said edge passageway along the interioredge,
 25. A static structure of claim 18 further comprising at least onesaid edge passageway of claim
 22. 26. The structure anchoring method ofclaim 22 wherein said anchoring strapping means is a metal band.